Tundish Metering Nozzles

Dyson Technical Ceramics manufactures a comprehensive range of high performance Zirconia Tundish Metering Nozzles used mainly in the continuous casting of steel billets. Tundish Nozzles usually comprise a zirconia inner nozzle (often referred to as a “zirconia insert”) with a lower grade outer body such as Alumina, Zircon or Bauxite.

For more detailed information please see below or alternatively, download one of our brochures.

Product Description

Dyson Technical Ceramics manufactures a comprehensive range of high performance Zirconia Tundish Metering Nozzles used mainly in the continuous casting of steel billets. Tundish Nozzles usually comprise a zirconia inner nozzle (often referred to as a “zirconia insert”) with a lower grade outer body such as Alumina, Zircon or Bauxite.

Solid tundish nozzles were historically supplied but in recent years most steel plants have shown preferences towards a composite nozzle design for reasons of economy. The composite nozzle method of manufacture, pioneered by Dyson allows for the nozzle to be manufactured without the use of cement jointing, by pressing the outer material directly around the zirconia insert. This method of manufacture provides a reliable system with no risk of steel leakage between the insert and outer body.

Dyson Zirconia ZPZ™ Tundish Nozzle Inserts

Dyson’s reputation and success is mainly based on our range of ZPZ™, ultra high performance zirconia inserts. The performance of this type of nozzle is in some instances exceptional with many casting sequence records achieved. Advanced forming methods confer on the nozzles both high and uniform densities.

The ultra-high densities associated with the ZPZ family of products impart excellent erosion resistance even in the most severe casting environments. Consistent casting speeds are achieved and the products have a high resistance to oxygen lancing.

For more information on the materials we offer please click on the “Material Selection” tab.

Flexibility – Ability to reduce the casting speed by changing the nozzle diameter or closing strands to reduce metal flow.

Exchangeable metering systems include an upper and lower nozzle on each tundish strand. The upper nozzle is located within the tundish lining and conveys steel to the controlling lower nozzles.

Upper Nozzles(also referred to as: Stationary nozzles, Superior Nozzles, Inner Nozzles)
As upper nozzles are located within the tundish lining, these nozzles are fixed and must be able to withstand long sequence times. Therefore it is recommend that an ultra-high density ZPZ insert is used. The ZPZ insert provides excellent erosion resistance, allowing extended casting sequences. The ZPZ insert can be supplied with the following outer configurations:

Lower Nozzles(also referred to as: exchangeable nozzles, flying nozzles, shooting nozzles, quick-change nozzles, outer nozzles, inferior nozzles)The lower nozzle is located within an assembly that is fixed to the bottom of the Tundish. Once the nozzle wears out or the casting speed needs to be reduced the lower nozzle can be exchanged with either a new lower nozzle or a blank nozzle to shut the strand off entirely. Lower nozzles must be erosion resistant to enable long casting sequences. In addition to this lower must be able to withstand cold start practises or oxygen lancing. Therefore a balance of erosion resistance and thermal shock resistance must be achieved. This balance is achieved with Dyson’s ZPZ-D zirconia inserts. ZPZ-D provides high density for erosion resistance, yet the unique granulometry of the material gives the nozzle enhanced thermal shock resistant properties.

Blank NozzlesNozzle blanks consist of a metal can and an Alumina body. No Zirconia inserts are used. Blank nozzles are used to stop the flow of metal for a given tundish strand. Shutting the flow of metal to a certain strand will reduce the flow rate, slowing down the production and allowing other areas of the steel plant to catch up. The blank can also be used as a safety mechanism; if the steel casting finds one strand to be problematic the strand can be shut almost instantly. The strand can then be restarted by exchanging the blank with a new lower nozzle.

The design of tundish nozzles vary according to the system manufacturer or the individual needs of the steel plant. Dyson Technical Ceramics manufacturers a wide range of tundish nozzle designs for both exchangeable metering systems and standard metering systems. Dyson’s tundish metering nozzles are supplied to exacting tolerances, ready for immediate use.

To talk to our experts about our tundish nozzles or to enquire please visit the contact us page.

Zirconia Insert Qualities

It is important to choose the correct zirconia insert material to maximise nozzle performance. Our experts are on hand to help you decide the most optimum material qualities for your equipment and casting practises, please contact us to discuss our recommendations.

Below is a guide to our Zirconia insert qualities:

Zirconia ZPZ Series of Products

Recommended for exchangeable metering systems and standard metering systems which casting sequences of 12 hours or more. ZPZ-LS is recommended for high Manganese steel grades.

ZPZ-LS

ZPZ

ZPZ-E

ZPZ-D

General Properties

Apparent Porosity (%)

3.5

6.5

8.5

11.5

Bulk Density (g/ml)
(lb/ft3)

5.5
343

5.3
331

5.2
325

5.02
313

Chemical Analysis

SiO2

0.2

0.5

0.2

1.1

Fe2O3

0.05

0.1

0.2

0.2

MgO

2.4

2.4

2.5

2.4

ZrO2 + HfO2

97.0

96.3

96.6

94.5

Traditional (Non-ZPZ) Zirconia Insert Materials

Used in short-medium standard (non-system) metering systems. Can also be used in lower/exchangeable tundish nozzles with a target life of approximately 8 hours or less.

ZIRCONIA MX

ZIRCONIA SUPER M

ZIRCONIA P

General Properties

Apparent Porosity (%)

15.5

18.5

16.0

Bulk Density (g/ml)
(lb/ft3)

4.73
295

4.60
287

4.73
295

Chemical Analysis

SiO2

1.6

1.7

1.2

Fe2O3

0.1

0.1

0.1

CaO

0.2

0.1

1.9

MgO

2.5

4.8

0.1

ZrO2 + HfO2

94.2

92.5

95.5

Tundish Nozzle Outers

Material selection depends largely on the nozzle design, therefore please contact us and one of our experts will help you choose the outer material most suitable for your nozzle design and casting practises. Below is a list of Dyson's typical nozzle outer material. Non ZPZ Zirconia can also be used as nozzle outers.

PH850

PH850C4

ZIRCON-F

DYCAST 1800F

Insert Moulding Method

Co-moulded

Co-moulded

Cemented

Cast

General Properties

Apparent Porosity (%)

18.0

16.5

19.0

23.2

Bulk Density (g/ml)
(lb/ft3)

2.87
179

2.88
179

3.70
231

2.86
179

Chemical Analysis

SiO2

9.5

7.3

33.0

0.1

Fe2O3

1.5

1.4

0.2

0.1

Al2O3

82.0

82.0

1.7

96.5

ZrO2 + HfO2

-

-

64.0

-

Cr2O3

-

4.4

-

-

Submit an Enquiry

To submit an enquiry for Dyson's Tundish Nozzles please complete the contact for below. In your message please provide as much information as possible about your casting practises, current supply and estimated usages.

Your name

Your email address *

Company name *

Subject

File submission (Max. 2mb)

Your Message *

Related Products

Dyson Technical Ceramics™ manufactures a wide range of high performance pressed Zirconia Crucibles, based upon partially stabilised Zirconia. Zirconia Crucibles are often used in the precious metals, aerospace and biomedical industries. Applications include the investment casting of Nickel, Cobalt and Chrome containing alloys, along with high temperature melting and refining of Platinum Group Metals (PGMs’).

Dyson Technical Ceramics are principle manufacturers of high performance Zirconia Atomising Nozzles for use in the Powder Metallurgy industry. Atomising nozzles are available in a wide range of shapes and sizes, many to the requirements of individual customers.

Applications include the casting and atomisation of Ferrous and Non Ferrous melts.

One of the principle features of Zircatom™ nozzles is their close dimensional accuracy, which promotes stable flow characteristics under the most arduous conditions. The addition of specially selected stabilising oxides provides high strength, excellent erosion resistance and minimal cracking due to thermal shock/rapid cooling.

Dyson Technical Ceramics™ Zirconia Ceramics Filters are used in the filtration of Steel and Nickel/Cobalt based superalloy castings. DysonTC’s Zirconia Ceramic Filters offer resistance to high temperatures, while maintaining excellent erosion resistance. The fine textures of the filters provide excellent filtration properties, giving the caster cleaner melts and reducing the need for grinding/machining. Advanced production techniques help to give the filters an even 3D lattice, resulting in a smooth, non-turbulent melt flow.

Incorporating low iron, pre-calcined dense grain materials, this product is formulated to provide high strength, high abrasion resistance, low porosity and high refractoriness combined with a high resistance to glass furnace carryover, vapours and solids.

SDR-F

A dry pressed high strength abrasion resistant firebrick with good dimensional tolerance. SDR-F is a high performance firebrick which finds application where resistance to glass furnace carryover in solid or vapour forms is required.

Dyson Technical Ceramics manufactures a range of high density zirconia sliding gate plate inserts, which are used within sliding gate plate applications. The inserts are generally used within a cast or pressed refractory plate.

Sliding Gate Plate inserts are an excellent solution to increasing the life span of sliding gate plates. Once a sliding gate plate becomes worn,
the worn material can be removed and a high density DysonTC Zirconia Plate insert can be cemented/cast in its place, therefore extending the life of the sliding gate plate.

Complimenting Dyson’s range of crucibles Dyson Technical Ceramics also offer thermal insulating Dypack™ backing material, which can be used in air and induction melting applications. Also referred to as “Ramming Material” or “Crucible Back-up”, it creates a safety barrier in the unlikely event of a crucible failure. The crucible back-up also insulates the crucible, helping reduce changes in temperature that can cause thermal stress.

Dyson Technical Ceramics™ Foundry Ladle Nozzles are available in a range of Alumina grade material qualities to suit casting requirements. Our nozzles are made from high purity raw materials to promote higher erosion resistance to metals and alloys.

A combination of excellent cosmetic appearance and dimensional accuracy promotes stable casting conditions. All our nozzles are available in a wide variety of bore sizes and are widely used in bottom pour ladle applications, where flow control is of paramount importance. Our efficient manufacturing techniques enable our clients to get the products they need, when they are needed.